Methods for transferring items

ABSTRACT

A method of transferring items comprises feeding items toward a carrier mechanism from one or more input streams and engaging void areas in the items with one or more rods extending from the carrier mechanism. The method further comprises manipulating the carrier mechanism relative to the one or more input streams into a position substantially aligned with one or more output streams and feeding the items to the one or more output streams. The configuration of items in each input stream is different than the configuration of items in each output stream.

CROSS REFERENCE TO RELATED APPLICATION(S)

This application claims the benefit of U.S. Provisional Application No.61/536,220, filed Sep. 19, 2011.

FIELD

The present disclosure generally relates to methods for transferringitems, and more particularly, relates to methods for transferring itemsbetween one or more input streams and one or more output streams.

BACKGROUND

During manufacturing processes, it is often necessary to group, orient,arrange, and/or sort items for packaging or for other downstreamoperations. Such operations can be cumbersome if the items do not haveflat sides, do not fit together in an orderly fashion, and/or if theitems are hard to control (e.g., the products do not remain stationaryon a flat conveyor), for example. Currently technologies use guiderails, stacking apparatuses, grouping apparatuses, and/or layeringdevices, for example, to handle the items. These technologies usuallyengage outer surfaces of the items during handling. Such currenttechnologies have drawbacks, such as complexity. Further, currenttechnologies usually do not provide great process flexibility and may bea limiting factor in production rates. In some instances, manufacturingequipment can be designed to be quite complex and perform a great numberof functions or can be designed to be simpler and only perform limitednumber of functions. It would be beneficial to provide methods andmechanisms for transferring items that improve the state of the art, donot damage the outer surface of the items, do not limit the productionrate of a manufacturing line, and provide for great flexibility in amanufacturing process.

SUMMARY

In one embodiment, the present disclosure is directed, in part, to amethod of transferring items. The method comprises feeding items towarda carrier mechanism comprising a plurality of rods extending therefromfrom one or more input streams, engaging void areas defined in the itemswith at least some of the plurality of rods, manipulating the carriermechanism relative to the one or more input streams into a positionsubstantially aligned with one or more output streams, and feeding theitems onto the one or more output streams. The items in each inputstream have a different configuration than the items in each outputstream.

In another embodiment, the present disclosure is directed, in part, to amethod of transferring packaged items. The method comprises feedingpackaged items toward a carrier mechanism from one or more inputstreams, engaging non-product containing areas of the packaged itemswith supports extending from the carrier mechanism, manipulating thecarrier mechanism relative to the one or more input streams into aposition substantially aligned with one or more output streams, andfeeding the packaged items onto the one or more output streams. Theconfiguration of the packaged items in the one or more input streams isdifferent than the configuration of the packaged items in the one ormore output streams.

In yet another embodiment, the present disclosure is directed, in part,to a method of transferring items. The method comprises feeding itemstoward a carrier mechanism from one or more input streams, engaging voidareas in the items with at least some of a plurality of rods extendingfrom the carrier mechanism, radially expanding at least one of the rods,and rotating the carrier mechanism relative to the one or more inputstreams into a position substantially aligned with one or more outputstreams. The method further comprises radially contracting the at leastone rod and discharging the items onto the one or more output streamsusing a pusher apparatus. The configuration of the items in each of theinput streams is different than the configuration of the items in eachof the output streams.

BRIEF DESCRIPTION OF THE DRAWINGS

The above-mentioned and other features and advantages of the presentdisclosure, and the manner of attaining them, will become more apparentand the disclosure itself will be better understood by reference to thefollowing description of non-limiting embodiments of the disclosuretaken in conjunction with the accompanying drawings, wherein:

FIG. 1 is a perspective illustration of a transfer mechanismtransferring items between an input stream and an output stream inaccordance with one non-limiting embodiment;

FIG. 2 is a top view illustration of a transfer mechanism in accordancewith one non-limiting embodiment;

FIG. 3 is a top view illustration of another transfer mechanism inaccordance with another non-limiting embodiment;

FIG. 4A is a perspective view of a carrier mechanism comprising a baseand a plurality of rods extending from the base in accordance with onenon-limiting embodiment;

FIG. 4B is another perspective view of a carrier mechanism having a baseand a plurality of rods extending from the base in accordance with onenon-limiting embodiment;

FIG. 5A is an example loading sequence of a carrier mechanism inaccordance with one non-limiting embodiment;

FIG. 5B is an example unloading sequence of the carrier mechanism ofFIG. 5A in accordance with one non-limiting embodiment;

FIG. 6A is an example of another loading sequence of a carrier mechanismin accordance with one non-limiting embodiment;

FIG. 6B is an example unloading sequence of the carrier mechanism ofFIG. 6A in accordance with one non-limiting embodiment;

FIGS. 7-11 are top view illustrations of transfer mechanisms inaccordance with various non-limiting embodiments;

FIG. 12 is a front view of an example support comprising a plurality ofnubs thereon in accordance with one non-limiting embodiment;

FIG. 13 is a top view illustration of another transfer mechanism inaccordance with one non-limiting embodiment;

FIG. 14A is an end view of a pusher apparatus configured to disengageitems from a carrier mechanism in accordance with one non-limitingembodiment;

FIG. 14B is a side view of the pusher apparatus of FIG. 14A inaccordance with one non-limiting embodiment;

FIG. 14C is another side view of the pusher apparatus of FIG. 14A inaccordance with one non-limiting embodiment;

FIGS. 15A and 15B are side views of an expanding rod configured for usewith the carrier mechanism of the present disclosure in accordance withvarious non-limiting embodiments; and

FIGS. 16A and 16B are side views of a rod engaged with a movable collarconfigured for use with the rods of the carrier mechanism in accordancewith various non-limiting embodiments.

DETAILED DESCRIPTION

Various non-limiting embodiments of the present disclosure will now bedescribed to provide an overall understanding of the principles of thestructure, function, manufacture, and use of the methods and mechanismsfor transferring items disclosed herein. One or more examples of thesenon-limiting embodiments are illustrated in the accompanying drawings.Those of ordinary skill in the art will understand that the methods andmechanisms for transferring items described herein and illustrated inthe accompanying drawings are non-limiting example embodiments and thatthe scope of the various non-limiting embodiments of the presentdisclosure are defined solely by the claims. The features illustrated ordescribed in connection with one non-limiting embodiment can be combinedwith the features of other non-limiting embodiments. Such modificationsand variations are intended to be included within the scope of thepresent disclosure.

“Fiber” as used herein means an elongate physical structure having anapparent length greatly exceeding its apparent diameter (i.e. a lengthto diameter ratio of at least about 10.) Fibers having a non-circularcross-section and/or tubular shape are common; the “diameter” in thiscase can be considered to be the diameter of a circle havingcross-sectional area equal to the cross-sectional area of the fiber.More specifically, as used herein, “fiber” refers to fibrousstructure-making fibers. The present disclosure contemplates the use ofa variety of fibrous structure-making fibers, such as, for example,natural fibers or synthetic fibers, or any other suitable fibers, andany combination thereof.

“Fibrous structure” as used herein means a structure that comprises oneor more fibers. Nonlimiting examples of processes for making fibrousstructures include known wet-laid papermaking processes and air-laidpapermaking processes. Such processes typically comprise the steps ofpreparing a fiber composition in the form of a suspension in a medium,either wet, more specifically aqueous medium, or dry, more specificallygaseous, i.e. with air as medium. The aqueous medium used for wet-laidprocesses is oftentimes referred to as a fiber slurry. The fibroussuspension is then used to deposit a plurality of fibers onto a formingwire or belt such that an embryonic fibrous structure is formed, afterwhich drying and/or bonding the fibers together results in a fibrousstructure. Further processing the fibrous structure can be carried outsuch that a finished fibrous structure is formed. For example, intypical papermaking processes, the finished fibrous structure is thefibrous structure that is wound on the reel at the end of papermakingand can subsequently be converted into a finished product (e.g. asanitary tissue product).

“Sanitary tissue product” as used herein means one or more finishedfibrous structures, converted or not, that is useful as a wipingimplement for post-urinary and post-bowel movement cleaning (e.g.,toilet tissue and wet wipes), for otorhinolaryngological discharges(e.g., facial tissue), and multi-functional absorbent and cleaning uses(e.g., paper towels). The sanitary tissue products can be embossed ornot embossed and creped or uncreped.

In various embodiments, transfer mechanisms that can transfer one ormore items from one or more input streams or conveyors (togetherreferred to herein as “streams”) to one or more output streams areprovided by the present disclosure. Methods of transferring one or moreitems between one or more input streams and one or more output streamsare also provided. The transfer mechanisms can each comprise a turret(or other rotating member), optionally one or more arms, and one or morecarrier mechanisms. The one or more arms can extend from the turret andthe one or more carrier mechanisms can extend from the arms. In oneembodiment, the arms can be eliminated and the carrier mechanisms can beengaged with and/or extend from the turret. The turret can rotate tomove the arms and the carrier mechanism or the arms and the carriermechanism can rotate about the turret. In other various embodiments, arobot, for example, can be used in place of the turret to move and/orrotate the one or more carrier mechanisms.

In various embodiments, the transfer mechanisms of the presentdisclosure can be configured to transfer a plurality of items betweenone or more input streams and one or more output streams. Such items caninclude, but are not limited to, sanitary tissue products, rolls ofsanitary tissue products, packaged sanitary tissue products—whetherpackaged in paperboard containers or films, rolls of wet wipes orcleaning wipes, bottles, containers, diapers, and sanitary napkins, forexample.

In one embodiment, referring to FIG. 1, an example transfer mechanism 10is illustrated. The transfer mechanism 10 is configured to receive oneor more input streams 12 of items 14 and transfer the items 14 to one ormore output streams 16 of the items 14. The transfer mechanism 10, orportions thereof, such as a carrier mechanism, for example, canmanipulate, rotate, and/or move any suitable distance or rotationaldegree (e.g., an output stream can be positioned 160 degrees from aninput stream) such that the items 14 can be transferred from the inputstream 12 to the output stream 16. This can allow for better processflow or manufacturing facility floor space management. In variousembodiments, the configuration or arrangement of the items 14 in eachinput stream 12 can be different than the configuration or arrangementof the items 14 in each output stream 16. For example, each input stream12 can have 1 item three rows deep while an output stream 16 can havethree columns of items 14, 2 rows deep, and 3 rows wide.

In one embodiment, still referring to FIG. 1, the transfer mechanism 10can comprise a turret 18. The turret 18 can be fixed in a non-rotatableor non-moveable position or can be moveable and/or rotatable through theuse of actuators. Any other suitable mechanism for moving and/orrotating one or more carrier mechanisms or having the same rotate aboutit can be used in place of the turret 18. The turret 18 can have alongitudinal axis 20. One or more arms 22 can extend from the turret 18and/or can be attached to the turret 18. Each of the arms 22 can befixedly or rigidly attached to the turret 18. In such an embodiment, theturret 18 can rotate about its longitudinal axis 20 through the use ofone or more actuators to manipulate or rotate the arms 22. In othervarious embodiments, the arms 22 can be rotatably attached to the turret18 and can rotate about the longitudinal axis 20 and relative to thefixed turret 18. In such an embodiment, the arms 22 can be operablyengaged with one or more actuators (not illustrated) configured torotate the arms 22 about the turret 18. The actuator can be a motoroperably coupled to a drive chain or belt or a rack and pinion system.The arms 22, whether rotated by the turret 18 or rotated about theturret 18, can make a full revolution (i.e., 360 degree movement) aboutthe turret 18. In other embodiments, the arms 22 may only make a partialrevolution about the turret 18 (e.g., 180 degrees). In one embodiment,the arms 22 can rotate in the clockwise direction and/or in thecounter-clockwise direction about the longitudinal axis 20 of the turret18. Although two arms 22 are illustrated in FIG. 1, one arm 22 can beprovided or more than two arms 22 can be provided on a single turret 18.In other various embodiments, the arms 22 can be positioned around, oraround at least a portion of, the circumference or perimeter of theturret 18. In various embodiments, if two or more of the arms 22 areprovided on the turret 18, the arms 22 can be positioned on the turret18 at different heights on the turret 18 so as to allow the arms 22 torotate about the turret 18 independent of the position of another arm22. In other various embodiments, if two or more of the arms 22 areprovided on the turret 18, the arms 22 can be positioned at the sameheight on the turret 18. Each of the arms 22 can be formed with acarrier mechanism 24 or can be engaged with the carrier mechanism 24. Inan embodiment comprising two of the arms 22 (each engaged with a carriermechanism 24) at different heights on the turret 18, the transfermechanism can transfer items 14 from a first input stream 12 at a firstheight on the turret 18 and discharge the items 14 onto an output stream16 at the first height using the first arm 22 and the first carriermechanism 24 and can transfer items 14 from a second input stream 12 ata second height on the turret 18 and discharge the items 14 onto anoutput stream 16 at the second height using the second arm 22 and thesecond carrier mechanism 24.

In one embodiment, still referring to FIG. 1, the carrier mechanism 24can be engaged with or formed with the one or more arms 22 or attacheddirectly to the turret 18. The carrier mechanism 24 can comprise a base26 and a plurality of rods 28 extending from the base 26 and/or operablyengaged with the base 26 through the use of one or more actuators.Additional details regarding the rods 28 are discussed below. In otherembodiments, the rods 28 may not be provided and the base 26 cancomprise a plurality of item receiving areas or spaces and/or itemreceiving shelves. The item receiving areas or spaces and/or the itemreceiving shelves can be adjustable in size or spacing such that theycan be configured to receive items 14 having different dimensions. Forexample, a first shelf may be movable relative to a second shelf toreceive an item 14 having larger or smaller dimensions. In oneembodiment, the shelves can be configured to receive items that arebottles, containers, and/or sanitary tissue products. In such anembodiment, once the shelves receive the bottles, containers, and/orsanitary tissue products, at least one shelf can move relative toanother shelf to apply a force to the bottles, containers, and/orsanitary tissue products to aid in retaining the bottles, containers,and/or sanitary tissue products on the carrier mechanism 24 duringrotation, manipulation, or movement of the carrier mechanism 24 (e.g.,movement between one or more input streams and one or more outputstreams). The bottles, containers, and/or sanitary tissue products canbe removed from the shelves and discharged onto an output stream using apusher apparatus, such as a linear actuator, for example. The pusherapparatus can engage the bottles, containers, and/or sanitary tissueproducts and essentially push or force them onto the output stream.Other mechanisms or areas can also be provided on the base 26 forreceiving other items. In one embodiment, the receiving areas or spacesand/or the item receiving shelves can each comprise a backstop or wallto prevent the bottles, containers, and/or sanitary tissue products frommoving to deeply with the receiving areas or spaces and/or the itemreceiving shelves.

In one embodiment, referring to FIGS. 2 and 3, a guide 30 can bepositioned around, or at least partially around, the transfer mechanism10. In various embodiments, the guide 30 can be used for safety orcontainment so that the items 14 do not slide out of or off of thecarrier mechanism 24 during movement, manipulation, or rotation of thecarrier mechanism 24. The guide 30 can define openings 32 therein thatalign with one or more input streams 12 and one or more output streams16. An opening 32 can be defined in the guide 30 for each input stream12 coming into the transfer mechanism 10 and for each output stream 16exiting the transfer mechanism 10. In one embodiment, the openings 32can be blocked with covers (not illustrated) if only one input streamand one output stream is desired for a particular manufacturing process.

In one embodiment, referring to FIG. 2, the arm 22 can be fixedlyattached to the turret 18 and the turret 18 can be rotatable about itslongitudinal axis 20. In such an embodiment, the turret 18 can rotate inthe clockwise and counter-clockwise direction, as indicated by arrow Aand the dashed lines, when loading items onto the rods 28. Although therods 28 are illustrated in various figures, those of skill in the artwill understand that the item receiving areas, spaces, and shelves canbe used in place of or in addition to the rods 28. The rotation ormanipulation of the turret 18 can occur during loading even if the rods28 are not provided on a carrier mechanism 24. In one example, if therods are in a 6 wide×1 high pattern and the input streams 12 each have asingle layer of items 14 entering the carrier mechanism 24, and thereare four input streams 12, the turret 18, and thereby the arms 22 andthe carrier mechanism 24, can rotate in the clockwise andcounter-clockwise direction to fill all of the rods 28 with items 14.The turret 18 can also move vertically when receiving the items 14 toload additional rows of the items 14 onto the carrier mechanism 24. Asanother example, if the rods 28 are in a 6 wide×3 high pattern and theinput streams 12 each have a single layer of items 14 moving towards thecarrier mechanism 24 at a time, and there are four input streams 12, toobtain additional rows of the items 14 on the carrier mechanism 24, theturret 18, the carrier mechanism 24, and/or the arms 22 can move upwardand/or downward in a vertical direction in addition to rotation aboutthe longitudinal axis 20. Also, at least some of the rods 28 can moverelative to each other before, during, or after the item loading processand/or an item unloading process. In one embodiment, the input streams12 can move upwardly and/or downwardly to load additional rows of theitems 14 onto the carrier mechanism 24 if the turret 18 is fixedvertically or if the turret 18 is movable vertically. In such anembodiment, the carrier mechanism 24, the arms 22, and/or the turret 18can be fixed vertically or can remain vertically stationary.

In one embodiment, one or more robots (not illustrated) can be used inplace of the turret 18. The robots can each have one or more of the arms22 attached to them and the arms 22 can each be attached to a carriermechanism 24. Alternatively, the robot can be directly attached to oneor of the more carrier mechanisms 24. The robots can have the ability toposition the arms 22 and/or the carrier mechanisms 24 relative to one ormore input streams 12, pick up items 14 on the rods 28, and move thearms 22 and/or the carrier mechanisms 24 into alignment with one or moreoutput streams 16 so that the items 14 can be discharged.

In other various embodiments, referring to FIG. 3, a portion of or allof the carrier mechanism 24 can move relative to the arm 22 and/orrelative to the turret 18. In one embodiment, the base 26 can moverelative to the arm 22. In such embodiments, the turret 18 can berotatable or fixed. In one embodiment, the carrier mechanism 24 can movein a direction perpendicular to the longitudinal axis 20 of the turret18. The carrier mechanism 24 can be movable in an essentiallyreciprocating fashion, in the directions indicated by arrow B, and asindicated by the dashed lines in FIG. 3. Although the carrier mechanism24 can move relative to the turret 18 to accept items 14, the turret 18can also rotate to provide additional maneuverability of the transfermechanism 10. In one example, if the rods 28 are in a 6 wide×1 highpattern and the input streams 12 each have one single layer of items 14moving toward the carrier mechanism 24, and there are four input streams12, the carrier mechanism 24 can move in the directions indicated byarrow B, and as indicated by the dashed lines in FIG. 3, such that allof the rods 28 can be filled. In various embodiments, if the rods 28 arein a 6 wide×2 high pattern, after filling a first row of items, theturret 18 and/or the carrier mechanism 24 can move vertically such thatadditional rows of items 14 can be loaded onto the rods 28. In othervarious embodiments, the carrier mechanism 24 can move relative to thearm 22 and/or the turret 18 to adjust the vertical height of the rods28. In still other various embodiments, the rods 28 can move relative tothe base 26 and/or relative to each other during the item loadingprocess.

In one embodiment, referring to FIGS. 1-4B, for example, one or aplurality of the rods 28 can extend outwardly from the base 26 in adirection away from the longitudinal axis 20 of the turret 18. Invarious embodiments, at least one of the rods 28 can be movable relativeto at least one other rod 28 to adjust the spacing between the rods 28and/or to compress, or slightly compress, items 14, such as rolls ofsanitary tissue products, for example, between the rods 28 duringmanipulation of the carrier mechanism 24. In one embodiment, all of therods 28 can be movable relative to at least one other rod 28. The rods28 can be moveable manually or through the use of actuators. The rods 28can be formed of a rigid material, such as a metal, for example, and, inone embodiment, can be coated or covered with a resilient material, suchas a rubber, for example. The resilient material can help the rods 28 ingripping items 14 and/or can protect the items 14 from crushing duringgripping. In another embodiment, the rods 28 can be at least partiallyformed of or coated with a low coefficient of friction material to aidthe rods 28 in engaging void areas within the cores of sanitary tissueproducts, for example. In one embodiment, the rods 28 can be positionedaround, or at least partially around, a circumference or perimeter ofthe turret 18.

In various embodiments, referring to FIGS. 4A and 4B, an example carriermechanism 24 can comprise a base 26 and a plurality of rods 28 extendingfrom the base 26. Although four rods 28 are illustrated as an example,any suitable number of rods 28 can extend from the base 26. Some exampleconfigurations of the rods 28 are a carrier mechanism 24 having a 4 rodwide×2 rod high configuration, a 4 rod wide×4 rod high configuration, a4 rod wide×6 rod high configuration, a 6 rod wide×2 rod highconfiguration, a 6 rod wide by 3 rod high configuration, or a 6 rod wideby six rod high configuration. In one embodiment, the base 26 cancomprise one or more plates 34 with slots 36 defined therein. A portionof the rods 28 can extend through the slots 36. In various embodiments,the base 26 can comprise a first set of plates 34 and a second set ofplates 34′. The two plates of the first set of plates 34 can move towardand away from each other in unison using a scissor-like linkage operablyengaged with an actuator, for example. Similarly, the two plates of thesecond set of plates 34′ can move toward and away from each other inunison using a scissor-like linkage operably engaged with an actuator,for example. The movement of the sets of the plates 34 and 34′ can allowthe rods 28 to be moved toward and away from each other in more than onedirection. FIG. 4A illustrates the rods 28 in a first position, whileFIG. 4B illustrates the rods 28 moved into a second position. In oneembodiment, at least one rod 28 or all of the rods 28 can have a pointedend portion, an arcuate end portion, and/or a conical portion 38. Such afeature can aid the rods 28 in engaging void areas within the items 14,such as void areas within the cores of rolled sanitary tissue products,for example, by essentially being self-centering during engagement. Eachrod 28 can comprise a backstop that prevents items 14 from beingpositioned to deeply on the rods 28. Further, each rod 28 can be anysuitable length depending on how many of the items 14 will be loadedthereon. In such an embodiment, the backstop may be adjustable about therods 28 depending on how many items 14 will be loaded onto the rods 28.In various embodiments, one or more of the rods 28 and/or one or more ofthe carrier mechanism 24 can be configured to tilt for additionalflexibility. In one embodiment, this tilting capability can be used toload additional rows of items 14, for example.

Most conventional sanitary tissue product handling mechanisms do notmanipulate the sanitary tissue products by void areas within the cores,but instead use outer surfaces or portions of the sanitary tissueproducts. By handling the sanitary tissue products, by void areas withinthe cores (and engaging inner surfaces of the cores with the rods 28),instead of by outer surfaces or portions thereof, the outer surfaces orportions of the sanitary tissue products can be maintained in anundamaged state, which is desirable when the sanitary tissue productsare on a shelf in a store.

One example of an item loading sequence is discussed below withreference to FIG. 5A. In this example, four input streams 12, each threeitems 14 deep, are fed into the carrier mechanism 24. This is an exampleof one group of items 14 being fed into the carrier mechanism 24. Inpractice, multiple groups of items 14 will be sequentially fed into thecarrier mechanism 24 on a continuous or a non-continuous basis. Thecarrier mechanism 24, in this instance, comprises six rods 28 wide, bythree rods 28 high (rods 28 are only illustrated in the first portion ofthe figure). The carrier mechanism 24 could also comprise six receivingspaces or shelves wide by three receiving spaces or shelves high. Therods 28, receiving spaces, or receiving shelves are represented in FIGS.5A-6B by squares. The rods 28 can extend from the center of the squares,for example. The length of any of the rods 28 discussed herein can besuitable for accepting the desired number of the items 14, such asrolled sanitary tissue products. First, a first item 14 from each of thefour input streams 12 is loaded onto the four bottom and left-most rods28. This leaves four input streams 12 that are two items 14 deep. Next,the carrier mechanism 24 is shifted to the right relative to theposition of the fixed input streams 12. In other embodiments, the inputstreams 12 could be moved to the right with the carrier mechanism 24being fixed. In still other embodiments, the plurality of rods 28 couldbe shifted to the right with the input streams 12 and the base 26 beingfixed. The two right-most input streams 12 of the items 14 are thenloaded onto the two remaining empty rods 28 in the bottom-most row ofthe rods 28. This leaves four input streams 12, with two input streams12 being one item 14 deep and the other two input streams 12 being twoitems deep. Then, the carrier mechanism 24 is shifted downwardly withrespect to the input streams 12 so that the four input streams 12 canfeed four items 14 onto the right-most four rods 28 in the second row ofrods 28. This leaves two input streams 12, each stream being one item 14deep. Next, the carrier mechanism 24 is shifted to the left. The items14 in the two remaining input streams 12 are then loaded onto theremaining two left-most empty rods 28 in the second row of rods 28.Thereby, the carrier mechanism 24 is loaded with a two high, by sixwide, by one item deep set of items 14. Of course, this process can berepeated to load a grouping of items 14 that is two or more items deep.

In one embodiment, referring to FIG. 5B, once the carrier mechanism 24has been manipulated or rotated from a position aligned, orsubstantially aligned, with the one or more input streams 12 into aposition aligned, or substantially aligned, with the one or more outputstreams 16, the items 14 can be unloaded from the carrier mechanism 24.In one embodiment, a pusher apparatus (see e.g., FIGS. 14A-14C, 16A, and16B and their description below), and/or other mechanisms, can be usedto unload the items 14. The items 14 can be unloaded onto the one ormore output streams 16 in two high by three wide item groupings. Invarious embodiments, the first grouping of items 14 can be unloaded ontoa first output stream and a second grouping of items 14 can be unloadedonto a second output stream. In other embodiments, the first grouping ofitems 14 can be unloaded onto the same output stream as the secondgrouping of items 14 either at the same time or at different timeintervals. It is important to note that all of the rods 28 or receivingspaces or shelves on each carrier mechanism do not always need to beused. Some can be left empty.

The carrier mechanism 24 can also be useful for layering items 14, suchas sanitary tissue products, for example. The carrier mechanism 24 canreceive four input streams 12 of items 14, then move vertically toaccept four additional input streams 12 of items 14, and then move intoa positioned aligned with, or substantially aligned with, one or moreoutput streams 16. The carrier mechanism 24 can then output items 14 twoor more layers high using a pusher apparatus or other device.

Another example of an item loading processes is discussed below withreference to FIGS. 6A-6B. In this example, three input streams 12, eachfive items 14 deep, are fed into the carrier mechanism 24. The carriermechanism 24, in this instance, comprises six rods 28 wide by three rods28 high (rods 28 are only shown in the first portion of the figure). Thecarrier mechanism 24 could also comprise six receiving spaces or shelveswide by three receiving spaces or shelves high. First, a first item 14from each of the three input streams 12 is loaded onto three rods 28 inthe bottom row of rods 28. This leaves three input streams 12 that arefour items 14 deep. Next, the carrier mechanism 24 is shifted to theright relative to the fixed position of the input streams 12. The inputstreams 12 could also be moved to the right with the carrier mechanism24 being fixed, as discussed above. The two right-most input streams 12of items 14 are then loaded onto the two right-most empty rods 28 in thebottom-most row of rods 28. This leaves three input streams 12, with twoinput streams 12 being three items 14 deep and the other input stream 12being four items deep. Then, the carrier mechanism 24 is shifteddownwardly with respect to the input streams 12 so that the three inputstreams 12 can feed three items 14 onto the right-most three rods 28 inthe second row of rods 28. This leaves three input streams 12, two inputstreams 12 being two items 14 deep and the other input stream 12 beingthree items 14 deep. Next, the carrier mechanism 24 is shifted to theleft and two items 14 are fed onto two rods 28 in the second row. Thisleaves three input streams 12, the end two input streams 12 being twoitems 14 deep and the middle input stream 12 being one item 14 deep. Thecarrier mechanism 24 is then shifted downwardly and three items 14 arefed onto three rods 28 in the top row of rods 28. This leaves a firstinput stream 12 that is a single item deep and a second input stream 12that is a single item deep (the items 14 in the middle input stream 12are now all loaded). The carrier mechanism 24 is then shifted to theleft so that the single item 14 in the left input stream 12 is fed ontoa rod 28 in the top row of rods 28. This leaves the right-most inputstream 12 with one item 14 deep. The carrier mechanism 24 is thenshifted to the right so that the remaining item 14 can be positioned onthe right-most rod 28 in the top row of rods 28. Thereby, the carriermechanism 24 is loaded a single item 14 deep, three items 14 high, andfive items 14 wide. Of course, this process can be repeated to load agrouping of items 14 more than one item deep. Instead of the carriermechanism 24 moving during loading, the input streams 12 can moverelative to the carrier mechanism 24.

In one embodiment, referring to FIG. 6B, when the carrier mechanism 24has been manipulated or rotated from a position aligned, orsubstantially aligned, with the input streams 12 into a positionaligned, or substantially aligned, with one or more output streams 16,the carrier mechanism 24 can be unloaded. In one embodiment, a pusherapparatus (see e.g., FIGS. 14A-14C, 16A, and 16B and their descriptionbelow) and/or other mechanisms, can be used to unload the items 14. Theitems 14 can be unloaded onto an output stream 16 by rows of rods 28 tooutput a grouping of items 14 that is one row deep, one row high, andfive rows wide. Therefore, in this example, three groupings of items 14can be unloaded. In various embodiments, the first grouping of items 14can be unloaded onto a first output stream 16, a second grouping ofitems 14 can be loaded onto a second output stream 16, and a thirdgrouping of items 14 can be unloaded onto a third output stream 16. Inother embodiments, the first grouping of items 14, the second groupingof items 14, and the third grouping of items 14 can all be unloaded ordischarged onto the same output stream 16 at different time intervalsand/or sequentially.

In various embodiments, each of the rods 28 can move toward and awayfrom at least one other rod 28 to slightly compress the items 14 on therods 28 at least during manipulation or rotation of the transfermechanism 28. This can maintain the items 14 on the rods 28 despiteforces of acceleration created during rotation or manipulation of thetransfer mechanism 10. Stated another way, the compression of the items14 by the rods 28 can inhibit the items 14 from sliding off of the rods28 during rotation of the arms 22 or turret 18. The rods 28 can movetoward one another after the loading process and can then move away fromeach other when the carrier mechanism 24 is aligned with, orsubstantially aligned with, an output stream 16. In various embodiments,movements of the rods 28 can be individually controlled to provide theability to slightly compress certain items 14 without compressing othersor to adjust for the dimensions (e.g., diameters) of the items 14 to beloaded.

The above are merely examples of loading and unloaded items 14 fromcarrier mechanisms 24. Of course, a multitude of configurations andprocesses are possible and are within the scope of the presentdisclosure. In one embodiment, an input stream 12 can have a differentnumber of items 14 than an output stream 16. For example, in FIGS. 5Aand 5B, each input stream 12 has one item 14 being loaded at a time,while each output stream 16 has six items 14 being unloaded at a time.In FIGS. 6A and 6B, each input stream 12 has one item being loaded at atime, while each output stream 16 has five items being unloaded at atime. In various embodiments, the items 14 in an input stream 12 canhave a different configuration as the items 14 in the output stream 16.Although each input stream 12 is illustrated as a single layer of items14, each input stream 12 could comprise multiple layers of items 14 thatare loaded simultaneously or independently, for example.

Various example configurations of transfer mechanisms will now bediscussed in reference to the figures. In one embodiment, referring toFIG. 7, a transfer mechanism 10 can comprise two arms 22 that can eachrotate about a turret 18 or that are rotated by the turret 18. The inputstream 12 and the output stream 16 are positioned about 180 degreesapart from each other. The transfer mechanism 10 can receive four inputstreams 12 of one item 14 at a time and can output a grouping of items14 6 items wide at a time. In various embodiments, the transfermechanism 10 illustrated in FIG. 8 comprises three arms 22 rotatingabout a turret 18 or that are rotated by the turret 18. The transfermechanism 10 has two separate locations of input streams 12 feedingtherein and one location of an output stream 16. The two separatelocations of input streams 12 in FIG. 8 are positioned about 90 degreesapart, for example, although the input streams 12 can be positioned atany other suitable angle with respect to each other. By providing twolocations of input streams 12, two different items 14 and 15 can beloaded onto the carrier mechanism 24 and discharged together at theoutput stream 16. In FIG. 8, the two different items 14 and 15 areindicated by shading. The two arms 22 and carrier mechanisms 24 alignedwith the two separate locations of input streams 12, as shown in FIG. 8,can be loaded, or partially loaded, simultaneously or independently, atdifferent time intervals. In other embodiments, only one position ofinput streams 12 may be used for loading with the other position ofinput streams 12 provided merely as a backup, for example. In stillother various embodiments, each carrier mechanism 24 can be partiallyloaded by one location of input streams 12 prior to being rotated into aposition aligned with, or substantially aligned with, one or more outputstreams 16.

In one embodiment, referring to FIG. 9, the transfer mechanism 10 can befed by multiple input streams 12 at a first location and can dischargetwo output streams 16 at different locations. In various embodiments,the first and second output streams 16 can be used to output items 14simultaneously or independently, at different time intervals. In oneembodiment, if the items 14 are sanitary tissue products, a first outputstream 16 can be used to send the sanitary tissue products to apalletizer and a second output stream 16 can be used to send thesanitary tissue products to a bundler, for example. The sanitary tissueproducts can be conveyed to the palletizer and/or the bundler using aconveyor, for example. In various embodiments, one of the output streams16 can also be used as an input stream 12 or as an output stream 16 andan input stream 12 depending on the desired manufacturing process. Thelocations of the input streams 12 and the locations of the outputstreams 16 can be positioned at any suitable angle away from each other.In one embodiment, the turret 18 (if the turret is rotating) may beconfigured to rotate in the clockwise and counter-clockwise directions.In another embodiment, the arms 22 (if the arms 22 are rotating about anon-rotatable turret 18) can be configured to rotate in the clockwiseand the counter-clockwise directions. In the example embodiment of FIG.9, at least one other input stream or output stream could be added toprovide the transfer mechanism 10 with greater flexibility in itscapabilities. In one embodiment, the carrier mechanism 24 can bepartially unloaded at a first output stream 16 and partially unloaded ata second output stream 16.

In one embodiment, referring to FIG. 10, the transfer mechanism may onlyhave one location of input streams 12 and one location of an outputstream 16. The input streams 12 may be positioned about 100 or lessdegrees away from the output stream 16, for example.

In one embodiment, referring to FIGS. 11 and 12, a transfer mechanism10′ can comprise a turret 18′, similar to or the same as the turret 18described above, one or more arms 22′, similar to or the same as thearms 22 described above, a carrier mechanism 24′ comprising a base 26′and two or more supports 40. The carrier mechanism 24′ can be engagedwith or formed with the arms 22′ similar to that described above withrespect to the carrier mechanism 24 and the arms 22. The base 26′ of thecarrier mechanism 24′ can be engaged with or formed with two or more ofthe supports 40. The supports 40 can extend outwardly from the base 26′in a direction away from the turret 18′ and away from the longitudinalaxis 20′ of the turret 18′. Example supports 40 are illustrated in FIGS.11 and 12. FIG. 12 is a front view of a single support 40. The two ormore supports 40 can optionally comprise one or more nubs 42 positionedabout a surface of each of the supports 40. The nubs 42 can be arrangedin one or more columns 44 and one or more rows 46 on each of thesupports 42. At least one nub 42 on a support 40 can be moveable withrespect to another nub 42 on the support 40. Alternatively, all or mostof the nubs 42 can be moveable relative to at least one other nub 42.This adjustability feature can allow the nubs 42 to be moved relative toone another to accommodate items, such as sanitary tissue products, forexample, having different diameters, void areas with the cores, and/orother dimensions. The nubs 42 can be comprised of or covered with aresilient material, such as a rubber, for example, to aid the nubs 42 inengaging and gripping items 14 or packaged items 14, and to at leastinhibit the nubs 42 from crushing portions of the items 14 or packageditems 14. In another embodiment, the nubs 42 can be at least partiallyformed of or coated with a low coefficient of friction materialconfigured to allow the nubs 42 to easily engage the items 14 orpackaged items 14. The supports 40 can be arranged on the base 26′ suchthat the nubs 42 on a first support 40 can face the nubs 42 on a secondsupport 40, as illustrated in FIG. 11. The supports 40 and the nubs 42can be used to engage sanitary tissue products 48 or packages ofsanitary tissue products 48 therebetween. In one embodiment, thesupports 40 can move relative to each other and/or relative to the base26′ using an actuator. In various embodiments, the supports 40 can beused to engage a plurality of sanitary tissue products 48 or a pluralityof packages of sanitary tissue products 48 at the same time. In oneembodiment, the nubs 42 can engage film wrapped packages of sanitarytissue products 48 in locations where the film does not contact thesanitary tissue products 48 within the film (i.e., non-productcontacting areas). These non-product contacting areas can be alignedwith, or substantially aligned with, void areas inside the cores of oneor more sanitary tissue products 48 or can be present in betweensanitary tissue products 48. Owing to the circular shape of sanitarytissue products 48, gaps can be provided intermediate a plurality ofsanitary tissue products 48. Such engagement of the non-productcontacting areas of a package of sanitary tissue product 48 can prevent,or at least inhibit, compression of the cores in a directionsubstantially perpendicular to a longitudinal axis of the cores. Ifcores of sanitary tissue products 48 are compressed, they can have anovate shape, which is generally undesirable for dispensing from acircular tube or bar. One or more of the nubs 42 can comprise endshaving pointed portions, arcuate portions, and/or conical portions toaid the nubs' engagement with the non-product containing areas of thepackages. Once the sanitary tissue products 48 and/or packages ofsanitary tissue products 48 are engaged with the nubs 42, the transfermechanism 10′ can manipulate or rotate from a positioned aligned with,or substantially aligned with, one or more input streams 12′ to aposition aligned with, or substantially aligned with, one or more outputstreams 16′. The support 40 can also pivot with respect to the base 26′and/or the arm 22′ to enable manipulation of the sanitary tissueproducts 48 or packages of the same from a vertical position into ahorizontal position or other suitable position. In one embodiment, thebase 26′ can comprise a pusher apparatus comprising, for example, alinear actuator configured to aid in discharging packages of sanitarytissue products 48 from the carrier mechanism 24. This pusher apparatuscan be located intermediate the first support 40 and the second support40.

In one embodiment, a transfer mechanism can be used in a method oftransferring packaged items. The method can comprise feeding packageditems, such as packaged sanitary tissue products 48, for example, towardthe carrier mechanism from one or more input streams, engaging thepackaged items with the two or more supports extending from the carriermechanism, manipulating the carrier mechanism relative to the one ormore input streams into a position substantially aligned with one ormore output streams, and feeding the packaged items onto the one or moreoutput streams. The configuration of the packaged items in the one ormore input streams can be different than the configuration of packageditems in the one or more output streams. The method can further compriseaccelerating the carrier mechanism between at least one of the inputstreams and at least one of the output streams and retaining thepackaged items in contact with the supports and/or the nubs during theaccelerating step. The nubs 42 can contact the non-product containingareas on the packages.

In one embodiment, referring to FIG. 13, an example transfer mechanism10″ is illustrated. The transfer mechanism 10″ can comprise a conveyor50 rotating about at least two rolls or rollers 52. The conveyor 50 canbe a belt, a chain, or other mechanical mechanism. A plurality of rods28″ can extend from the conveyor 50 and rotate with the conveyor 50. Inone embodiment, the rods 28″ can be accelerated about portions of theconveyor 50 (i.e., move at a speed faster than the conveyor 50) or“dwelled” about the conveyor 50 (i.e., move at a speed slower than theconveyor 50). In other embodiments, the rods 28″ can be coupled to theconveyor 50 when movement of the rods 28″ is desired and decoupled fromthe conveyor 50 when movement of the rods 28″ is not desired. Suchfeatures can help in joining the rods 28″ into groups, while loadingand/or unloading items 14″, for example, or separating the rods 28″ fromeach other at appropriate times. Although FIG. 13 illustrates a topview, the rods 28″ can be provided in single rod deep columns or can beprovided in multiple rod deep columns. In one embodiment, at the loadingand unloading areas, positive stops can be provided to ensure suitablealignment of the rods 28″ with the loading and/or unloading areas.

In operation, the conveyor 50 can rotate about the rolls or rollers 52,thereby rotating the rods 28″ about the rolls 52. The rods 28″ can haveany suitable length. The length can be appropriate for accepting oneitem 14″ or multiple items 14″. As an example, four input streams 12″ ofitems 14″ can be feed onto the rods 28″. If more than one rod deepcolumns of rods 28″ are provided, the rods 28″ can move upwardly anddownwardly relative to the conveyor 50 to load more than one row ofitems 14″. In other various embodiments, the rods 28″ can remainstationary on the conveyor 50 and the input streams 12″ can moveupwardly and downwardly relative to the conveyor to load multiple rowsof rods 28 with items 14″. Once loaded with the items 14″, the rods 28″can then be rotated about the conveyor 50 to a point where the items 14″can be outputted to one or more output streams 16″. The items 14″ in theinput streams 12″ can have a different configuration than the items 14″in the output streams 16″. For example, each input stream 12″ can have asingle layer of one item 14, while each output stream 16″ can havemultiple items 14 in multiple rows and columns.

In one embodiment, referring to FIGS. 14A-14C, an example pusherapparatus is disclosed. The pusher apparatus can be used to push orforce items, such as sanitary tissue products 48, for example, off ofthe rods 28 onto one or more output streams 16. The pusher apparatus cancomprise a plurality of fingers 54 extending between at least some ofthe rods 28. In one embodiment, a finger 54 can be positioned on eachside of one or more rods 28. In other embodiments, only one finger 54may be positioned adjacent to a rod 28. The fingers 54 can be operablyengaged with one or more linear actuators 56. In one embodiment, two ormore fingers 54 can be engaged with one linear actuator 56, for example.Referring to FIG. 14B, the linear actuator 56 can be configured to movethe fingers 54 relative to the base 26, as shown by arrow E, todisengage the sanitary tissue products 48 from the rods 28. In oneembodiment, referring to FIG. 14C, the base 26 can move relative to thefingers 54 such that less than all of the sanitary tissue products 48 onthe rods 28 may be discharged at one point in time. In other variousembodiments, the fingers 54 can be height adjustable relative to thebase 26 such that less than all of the sanitary tissue products 48 onthe rods 28 will be discharged at one point in time. In variousembodiments, one or more linear actuators 56 can be activatedindependently from one or more other linear actuators 56. This feature,along with the height adjustment of the fingers 54 and/or the base 26,can allow for discharge of a plurality of configurations of outputstreams 16.

In one embodiment, referring to FIGS. 15A and 15B, one or more of therods 28 can expand from a first position (FIG. 15A) into a secondposition (FIG. 15B) once rolls of sanitary tissue product 48 arepositioned on the rods 28. This expansion can function to hold the rollsof the sanitary tissue product 48 on the rods 28 during rotation of theturret 18, the arms 22, and/or the carrier mechanism 24, for example.After the rolls of the sanitary tissue products 48 are discharged fromthe rods 28, the rods 28 can retract into the position shown in FIG.15A. This expansion can be caused by an actuator within the rods 28.

In one embodiment, referring to FIGS. 16A and 16B, the rods 28 candefine one or more elongate slots 58. A collar 60 can be movable alongthe elongate slots 58 from a first position where the collar 60 islocated proximate to the base 26 (FIG. 16A) into a second position wherethe collar 60 is located distal from the base 26 (FIG. 16B). The collar60 and the elongate slots 58 can together be referred to as a pusherapparatus. The collar 60 can be moved along the elongate slots 58through the use of an actuator, such as a linear actuator, for example.The collar 60 can be used to discharge rolls of sanitary tissue products48 from the rods 28 at the appropriate time. If each rod 28 has a collar60, each collar 60 can be independently activated to enable variousconfigurations of sanitary tissue products 48 to be discharged at onepoint in time. In other embodiments, the collar 60 can be fixedlypositioned on one or more rods 28 and can have a plurality of openingsin an item-facing surface thereof. Air can be forced through theopenings at the appropriate time to discharge the sanitary tissueproducts 48 from the rods 28. In other various embodiments, belts orconveyors can be incorporated into one or more of the rods 28. The beltsor conveyors can engage the cores of the sanitary tissue products 48 onthe rods 28 and move them in a direction away from the base 26 todisengage the sanitary tissue products 48 from the rods 28. In stillother various embodiments, the rods 28 can have a series of openingstherein. Air can be forced through the openings to discharge thesanitary tissue products 48 from the rods 28.

In various embodiments, the rods 28 can have one or more sensorsthereon, therein, and/or associated therewith. The sensors can be usedto detect the presence of sanitary tissue products 48 thereon. Forinstance, a collar 60 of a rod 28 may not need to be actuated if asensor detects that sanitary tissue products 48 are not present on therod 28. In other various embodiments, the sensors can be configured todetect the number and size of the sanitary tissue products 48 on therods 28, for example.

In one embodiment, the various transfer mechanisms of the presentdisclosure, or other transfer mechanisms, can be used in methods fortransferring items, such as methods for transferring sanitary tissueproducts, for example. One example method can comprise feeding itemsonto or to toward a carrier mechanism from one or more input streams,wherein the carrier mechanism comprises a plurality of rods extendingtherefrom. The method further comprises engaging void areas (e.g., areasinside cores of sanitary tissue products) defined in the items with atleast some of the plurality of rods, manipulating the carrier mechanismrelative to the one or more input streams into a position substantiallyaligned with, or aligned with, one or more output streams, and feedingthe items onto the one or more output streams. The configuration ofitems in each input stream can be different than the configuration ofitems in each output stream. The method can further comprise moving thecarrier mechanism relative to the one or more input streams after theengaging step (above) and engaging void areas defined in a second groupof items in the one or more input streams with at least some of therods. One or more carrier mechanisms can simultaneously receive twoseparate input streams of items from different locations and/or canindependently, at different time intervals, receive two separate inputstreams of items. Similarly, one or more carrier mechanisms cansimultaneously feed two separate output streams of items orindependently, at different time intervals, feed two separate outputstreams of items. One or more carrier mechanisms can also feed a firstgroup of items to a first output stream and feed a second group of itemsto a second output stream, either simultaneously or independently, atdifferent time intervals. The first group of items can comprise the samenumber of items as the second group of items or a different number ofitems. A pusher apparatus can be used to discharge the items onto theone or more output streams.

The manipulating step of the method can comprise rotating the carriermechanism in a first direction from alignment with, or substantialalignment with, one or more input streams into alignment with a firstoutput stream and rotating the carrier mechanism in the first directioninto alignment with a second output stream. In addition to the rotating,the carrier mechanism can also be moved in a direction between the oneor more input streams and the one or more output streams. The directioncan be linear, non-linear, horizontal, vertical, and/or any othersuitable direction. In one embodiment, items can be stored on thecarrier mechanism, such as on the rods, for example, when the carriermechanism is in the process of moving between the one or more inputstreams and the one or more output streams.

In one embodiment, items can be fed onto at least some of the rods fromone or more input streams at a first speed (items per minute) and theitems can be discharged from at least some of the rods onto one or moreoutput streams at a second speed that is the same as or different thanthe first speed. Items can also be fed toward the carrier mechanism fromdifferent input streams at different to speeds or at the same speed.

Another method of using the transfer mechanisms of the presentdisclosure can comprise feeding items onto or toward a carrier mechanismfrom one or more input streams, engaging void areas (e.g., void areasinside cores of sanitary tissue products) in the items with at leastsome of a plurality of rods extending from the carrier mechanism,radially expanding one or more of the rods, rotating the carriermechanism relative to the one or more input streams into a positionsubstantially aligned with one or more output streams, radiallycontracting the one or more of the rods, and discharging the items ontothe one or more output streams using a pusher apparatus. Theconfiguration of items in each of the input streams can be differentthan the configuration of items in each of the output streams. The itemscan be rolled sanitary tissue products having void areas inside coresthereof. The engaging step can comprise positioning the rods at leastpartially or fully through the void areas in the cores. The method canfurther comprise moving the carrier mechanism in a first direction andin a second direction during the step of engaging the void areas in theitems with at least some of the plurality of rods.

The dimensions and values disclosed herein are not to be understood asbeing strictly limited to the exact numerical values recited. Instead,unless otherwise specified, each such dimension is intended to mean boththe recited value and a functionally equivalent range surrounding thatvalue. For example, a dimension disclosed as “40 mm” is intended to mean“about 40 mm.”

Every document cited herein, including any cross referenced or relatedpatent or application, is hereby incorporated herein by reference in itsentirety unless expressly excluded or otherwise limited. The citation ofany document is not an admission that it is prior art with respect toany invention disclosed or claimed herein or that it alone, or in anycombination with any other reference or references, teaches, suggests ordiscloses any such invention. Further, to the extent that any meaning ordefinition of a term in this document conflicts with any meaning ordefinition of the same term in a document incorporated by reference, themeaning or definition assigned to that term in this document shallgovern.

While particular embodiments of the present invention have beenillustrated and described, those of skill in the art will recognize thatvarious other changes and modifications can be made without departingfrom the spirit and scope of the invention. It is therefore intended tocover in the appended claims all such changes and modifications that arewithin the scope of this invention.

What is claimed is:
 1. A method of transferring items, wherein each itemcomprises a void area defined within said item, the method comprising:feeding items toward a carrier mechanism from one or more input streams,wherein the carrier mechanism comprises a plurality of rods extendingtherefrom; engaging the void areas defined within the items with atleast some of the plurality of rods; manipulating the carrier mechanismrelative to the one or more input streams into a position substantiallyaligned with one or more output streams; and feeding the items onto theone or more output streams, wherein the items in each input stream havea different configuration comprising a different depth than the items ineach output stream.
 2. The method of claim 1, comprising: moving thecarrier mechanism relative to the one or more input streams after theengaging step; and engaging the void areas defined within the items in asecond group of items in the one or more input streams with at leastsome of the rods.
 3. The method of claim 1, comprising simultaneouslyreceiving two separate input streams of items into the carriermechanism.
 4. The method of claim 1, comprising independently, atdifferent time intervals, receiving two separate input streams of itemsinto the carrier mechanism.
 5. The method of claim 1, comprisingsimultaneously feeding two separate output streams of items from thecarrier mechanism.
 6. The method of claim 1, comprising independently,at different time intervals, feeding two separate output streams ofitems from the carrier mechanism.
 7. The method of claim 1, comprising:feeding a first group of items to a first output stream; and feeding asecond group of items to a second output stream.
 8. The method of claim7, wherein the first group of items comprises more items than the secondgroup of items.
 9. The method of claim 1, wherein the step of feedingthe items onto the one or more output streams comprises using a pusherapparatus.
 10. The method of claim 1, comprising: feeding the items ontoat least some of the rods at a first speed from one or more inputstreams; and discharging the items from at least some of the rods ontoone or more output streams at a second speed, wherein the first speed isdifferent than the second speed.
 11. The method of claim 1, comprising:feeding the items onto at least some of the rods from a first inputstream at a first speed; and feeding the items onto at least some of therods from a second input stream at a second speed, wherein the firstspeed is different than the second speed.
 12. The method of claim 1,wherein the manipulating step comprises rotating the carrier mechanismin a first direction into alignment with a first output stream.
 13. Themethod of claim 12, wherein the manipulating step comprises rotating thecarrier mechanism in the first direction into alignment with a secondoutput stream.
 14. The method of claim 1, wherein the manipulating stepcomprises rotating the carrier mechanism and moving the carriermechanism in a direction.
 15. The method of claim 1, comprisingtemporarily storing the items on at least some of the rods intermediatethe one or more input streams and the one or more output streams.